John Deere Agriculture
6020 to 6920S Tractors Diagnostics
DIAGNOSIS AND TESTS SERVICE MANUAL 6020, 6120, 6220, 6320, 6420, 6420S, 6520, 6620, 6820, 6920, 6920S, 6020SE, 6120SE, 6220SE, 6320SE, 6420SE, 6520SE (Europe)
tm4726, April 2006
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
(g) by Belgreen
Table of contents FOREWORD VERSION DATE Section 210 - GENERAL INFORMATION Group 05 - Safety Information Section 211 - DIAGNOSTIC TROUBLE CODES Group ATC - ATC Diagnostic Trouble Codes Group BCU - BCU Diagnostic Trouble Codes Group BIF - BIF Diagnostic Trouble Codes Group ECU - ECU Diagnostic Trouble Codes Group EPC - EPC Diagnostic Trouble Codes Group JDL - JDL Diagnostic Trouble Codes Group PLC - PLC Diagnostic Trouble Codes Group PRF - PRF Diagnostic Trouble Codes Group SFA - SFA Diagnostic Trouble Codes Group SIC - SIC Diagnostic Trouble Codes Group SSU - SSU Diagnostic Trouble Codes Group TCU - TCU Diagnostic Trouble Codes Group TEC - TEC Diagnostic Trouble Codes Group TEI - TEI Diagnostic Trouble Codes Group UIC - UIC Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOMS Group 20 - Engine Group 40 - Electrical System Group 50 - SyncroPlus Transmission Group 51 - Power Reverser Transmission Group 53 - AutoPowr/IVT Transmission Group 55 - PowrQuad, PowrQuad Plus and AutoQuad Transmissions Group 56 - Drive Systems Group 60 - Steering and Brakes Group 70 - Hydraulic System Group 80 - Miscellaneous Group 90 - Operator′s Cab Section 213 - SYSTEM DIAGNOSTICS Group 45 - Electronics
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tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
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tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
(g) by Belgreen
Foreword This diagnostics manual is valid for the following tractor types: 6020, 6120, 6220, 6320, 6420, 6420S, 6520, 6620, 6820, 6920 and 6920S. SE tractors: 6020, 6120, 6220, 6320, 6420 and 6520. This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
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tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
GENERAL INFORMATION
(g) by Belgreen
Version date 01 December 2005
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tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
(g) by Belgreen
Section 210 - GENERAL INFORMATION Table of contents Group 05 - Safety Information ................................................................................................. 1 Recognize Safety Information ................................................................................................ 1 ”Important” Information ......................................................................................................... 1 ”Note” Information ................................................................................................................. 1 Prevent Machine Runaway ..................................................................................................... 1 Handle Fluids Safely-Avoid Fires ............................................................................................ 2 Prevent Battery Explosions .................................................................................................... 3 Prepare for Emergencies ........................................................................................................ 3 Prevent Acid Burns ................................................................................................................. 4 Avoid High-Pressure Fluids ..................................................................................................... 5 Service Cooling System Safely ............................................................................................... 5 Remove Paint Before Welding or Heating .............................................................................. 6 Avoid Heating Near Pressurized Fluid Lines ........................................................................... 7 Work In Ventilated Area ......................................................................................................... 7 Wear Protective Clothing ....................................................................................................... 8 Practice Safe Maintenance ..................................................................................................... 9 Park Machine Safely ............................................................................................................. 10 Use Proper Lifting Equipment ............................................................................................... 10 Construct Dealer-Made Tools Safely .................................................................................... 11 Support Machine Properly .................................................................................................... 11 Work in Clean Area .............................................................................................................. 12 Illuminate Work Area Safely ................................................................................................. 13 Service Machines Safely ....................................................................................................... 13 Use Proper Tools .................................................................................................................. 14 Service Tires Safely .............................................................................................................. 14 Service Front-Wheel Drive Tractor Safely ............................................................................ 16 Safety Information - Air Brake System ................................................................................. 16 Avoid Eye Contact With Radar ............................................................................................. 17 Keep ROPS Installed Properly ............................................................................................... 18 Replace Safety Signs ............................................................................................................ 18 Dispose of Waste Properly ................................................................................................... 19 Live With Safety ................................................................................................................... 20 Safety Measures on Electronic Control Units ........................................................................ 20
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tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
Section 210 - GENERAL INFORMATION
Group 05: Safety Information
Group 05 - Safety Information Recognize Safety Information
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices.
”Important” Information Information marked as IMPORTANT points out problems that may lead to machine damage. By following the directions given, these problems can be avoided.
”Note” Information When marked with NOTE the information given is more detailed or contains restrictions to directions given previously. On the other hand useful information may be given belonging to certain instructions without being directly connected to them.
Prevent Machine Runaway
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Section 210 page 1
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
Section 210 - GENERAL INFORMATION
Group 05: Safety Information
Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.
Handle Fluids Safely-Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. <- Go to Section TOC
Section 210 page 2
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
Section 210 - GENERAL INFORMATION
Group 05: Safety Information
Do not store oily rags; they can ignite and burn spontaneously.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies
Be prepared if a fire starts. <- Go to Section TOC
Section 210 page 3
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL
Section 210 - GENERAL INFORMATION
Group 05: Safety Information
Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. <- Go to Section TOC
Section 210 page 4
tm4726-DIAGNOSIS AND TESTS SERVICE MANUAL